Grid Route Clearance Control for Robotic Load and Fatigue Limits
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Solution Overview
Problem
Existing robotic movement systems in storage and retrieval facilities lack safety ratings and do not account for the loading and fatigue of grid pathways, leading to potential non-safety-critical damage and inefficiencies.
Innovation Solution
A controller system that determines routes and clearance for transporting devices on a grid-like structure, limiting loads and fatigue by identifying constraint areas susceptible to excess load or fatigue, and adjusting routes to avoid overloading, thereby ensuring safe and efficient movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic transporting devices operate freely on the grid-like structure without load limits, then productivity and movement speed are improved, but the grid structure suffers from excess loads and fatigue leading to damage
Solution Approach 1:
The system dynamically adjusts the operational parameters of transporting devices based on real-time grid structure conditions. The controller monitors grid cell status and adaptively modifies route assignments, speed limits, and load capacities to prevent excessive loading while maintaining optimal productivity when the grid can sustain higher loads.
Solution Approach 2:
The system implements continuous feedback loops where the controller receives status information from grid cells about current load levels and fatigue states. This feedback is used to adjust future routing decisions, speed assignments, and device allocations to prevent exceeding structural limits while maximizing operational efficiency within safe boundaries.
2Productivity
If the grid structure is designed with higher load capacity to support unrestricted robotic movement, then productivity is improved, but the initial construction cost and structural complexity increase
Solution Approach 1:
Rather than designing for maximum static load capacity throughout the entire grid, the system dynamically allocates load capacity based on real-time operational needs and historical usage patterns. Frequently used pathways receive higher capacity allocation while less-used areas operate with lower capacity requirements, optimizing the balance between productivity and structural complexity.
Solution Approach 2:
The grid structure implements non-uniform load capacity distribution where different grid cells have different load ratings based on their specific usage patterns and structural characteristics. This allows the system to provide high load capacity only where and when needed for productivity, rather than uniformly across the entire grid, reducing overall structural complexity.
3Reliability
If safety ratings are implemented for robotic movement functions, then reliability and human safety are improved, but the complexity of the control system increases
Solution Approach 1:
The transporting devices and grid cells autonomously monitor and report their own status, including load levels, fatigue states, and safety parameters. Each component performs self-diagnostics and communicates status to the controller, eliminating the need for complex external monitoring systems while maintaining high reliability through distributed intelligence.
Solution Approach 2:
The system performs preliminary safety assessments and route validations before authorizing robotic movement. The controller pre-calculates safe operating parameters, identifies potential hazard zones, and establishes protective measures in advance, preventing safety issues before they occur rather than reacting to them during operation.
Data Source
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AI summary
A controller is provided to control movement of a plurality of transporting devices. In particular, the controller limits the loads imparted on a grid of pathways structure by the plurality of transporting devices to prevent non-safety-critical damage from excess loads and/or fatigue. In particular, there is provided a controller arranged to control movement of a plurality of transporting devices, the plurality of transporting devices arranged to transport containers, the containers being stored in a facility, the facility arranged to store the containers in a plurality of stacks, the facility comprising a plurality of pathways arranged in cells so as to form a grid-like structure above the stacks, wherein the grid-like structure extends in a first direction and in a second direction, the plurality of transporting devices arranged to operate on the grid-like structure. The controller comprises a route determination unit arranged to determine a route from one location on the grid-like structure to another location on the grid-like structure for each transporting device and a clearance unit arranged to provide clearance for each transporting device to traverse a portion of the determined route. The controller also comprises a constraint area determination unit arranged to determine a plurality of constraint areas based on the grid-like structure and a calculation unit arranged to calculate a constraint limit in each constraint area. Moreover, at least one of the clearance unit is further arranged to grant or withhold clearance to a transporting device to traverse a portion of the determined route based on the calculated constraint limit in the particular constraint area, and the route determination unit is further arranged to determine a route for a transporting device from one location to another location traversing or not traversing a particular constraint area based on the calculated constraint limit in the particular constraint area.